Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
  • A23G3/02—Apparatus specially adapted for manufacture or treatment of sweetmeats or confectionery; Accessories therefor
  • A23G3/20—Apparatus for coating or filling sweetmeats or confectionery
  • A23G3/26—Apparatus for coating by tumbling with a liquid or powder, spraying device-associated, drum, rotating pan
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
  • A23L25/00—Food consisting mainly of nutmeat or seeds; Preparation or treatment thereof
  • A23L25/20—Food consisting mainly of nutmeat or seeds; Preparation or treatment thereof consisting of whole seeds or seed fragments
  • A23L25/25—Food consisting mainly of nutmeat or seeds; Preparation or treatment thereof consisting of whole seeds or seed fragments coated with a layer
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/10—Coating with edible coatings, e.g. with oils or fats
  • A23P20/12—Apparatus or processes for applying powders or particles to foodstuffs, e.g. for breading; Such apparatus combined with means for pre-moistening or battering
  • A23P20/13—Apparatus or processes for applying powders or particles to foodstuffs, e.g. for breading; Such apparatus combined with means for pre-moistening or battering involving agitation of the foodstuff inside a rotating apparatus, e.g. a drum

Definitions

• This invention relates to the continuous preparation of non-aggregated edible cores with crisp farinaceous coatings.
• Coated edible cores of this type are useful, for example, as snack food products such as coated nuts.
• Edible cores e.g., coatable food particulates
• materials that provide flavor or texture benefits include honey roasted nuts, chocolate covered nuts, chocolate or yogurt covered raisins, seasoned extruded particulates, candy coated chocolate particulates, and so on.
• Batch processing methods have historically been employed when coating individual edible cores with a farinaceous dough. Only when the current batch of edible cores is coated can the next batch be processed. Batch processing methods typically involve first adding an adhesive material to a batch of edible cores. When the edible cores are sufficiently coated with the adhesive, a farinaceous powder is applied to the adhesive-coated edible cores. The resulting coated edible cores are then baked or oil fried.
• the present invention relates to a continuous process for making non-aggregated edible cores which are uniformly coated with a crisp farinaceous material.
• a continuous process for making non-aggregated edible cores which are uniformly coated with a crisp farinaceous material.
• Such a process involves forming a tumbling bed of edible core particles that are treated within the tumbling bed to form a dough coating thereon. These dough- coated particles emerging from the tumbling bed are then cooked to form the desired coated products.
• the tumbling bed of edible cores used in this process has a longitudinal axis extending from an entrance end to an exit end of the bed.
• the individual edible cores travel through this bed from the entrance to the exit ends by rotating in a generally helical path along the longitudinal axis of the bed.
• the edible cores are coated within the bed by repeatedly tumbling through both a wet zone(s) and a dry zone(s) formed within the bed. These wet and dry zones are formed, respectively, by spraying the surface of the tumbling bed with a hydrating liquid and by dusting the surface of the tumbling bed with a farinaceous powder. Both the wet and dry zones thus formed are generally rectangular, but not overlapping, zones with the major dimensions of these rectangular zones being substantially parallel to the longitudinal axis of the tumbling bed.
• Aqueous liquid and farinaceous powder are applied, respectively, to the wet and dry zones of the tumbling, bed at rates which prevent aggregation of the edible cores and at rates which are suitable to form on the cores a dough-coating comprising flour, starch and sugar in a weight ratio of flour and starch to sugar of from about 0.5: 1 to 30: 1.
• the present invention relates to non-aggregated edible cores which are uniformly coated with a crisp farinaceous material.
• Such edible cores are those which result from cooking the dough-coated cores produced in the tumbling bed as hereinbefore described.
• Figure 1.1 illustrates a rotating drum containing a tumbling bed of edible cores being subjected to the dusting and spraying procedures of the present invention.
• Figure 1.2 illustrates a cross-sectional view of such a rotating drum.
• Figure 1.3 illustrates the parallel non-overlapping wet and dry zones of the tumbling bed.
• Figures 2.1, 2.2, 2.3 and 2.4 illustrate sample configurations of the parallel non- overlapping wet zones (WET) and dry zones (DRY) within the tumbling bed (BED) used in the present invention.
• the motion of the edible cores in the tumbling bed should conform with that which occurs when particulate material is continuously passed through a tilted rotating drum.
• edible cores can be continuously metered into an entrance end and out of an exit end of a tumbler coater (e.g., rotating drum).
• the edible cores within the tumbling bed are continuously and repeatedly rotated through the tumbling bed by way of the continuous rotating motion of the tumbler coater (see Figure 1.2). While rotating through the tumbling bed, the edible cores also travel along the longitudinal axis of the bed toward the exit end. of the tumbling bed. Individual core rotation thus moves in a generally helical path as they travel through the tumbling bed.
• Devices suitable for use in preparing the tumbling bed used in the process herein are those that can provide the edible core motion described hereinabove. That is, the device should have a means for rotating the edible cores while also moving them along the longitudinal axis of the bed that is substantially perpendicular to the rotating motion. Examples of suitable devices include rotating drums and troughs with internal augers.
• the tumbler coater for use in the process is a rotating drum.
• Suitable rotating drums include vented rotating drums, heated rotating drums, ribbed rotating drums, rotating drums with screw conveyance flight and variations thereof.
• the rotating drum should have ribbings or flights on its interior rotating surface or similar other means for facilitating the desired tumbling motion of the edible cores in the tumbling bed.
• drum as used herein means revolving pans and rotating drums. When a rotating drum is utilized, it preferably has its entrance end elevated above its exit end. The angle of elevation is typically from about 0.2o to 8o, more typically from about 2 to 5 degrees. This elevation acts as a means for moving the edible cores, which are rotating within the drum, along the longitudinal axis of the rotating drum toward the exit end of the drum. Less preferably, the means for moving the edible cores along the longitudinal axis can be by screw conveyance flight, internal auger or other similar means.
• any size or scale of rotating drum can be used in the instant process.
• conventional rotating drums having internal dimensions ranging from about 6 ft x 2 ft to 15 ft x 3ft can be employed.
• the coating operation can be practiced in a single rotating drum, in a series of rotating drums (see Figure 2.4), or repeated within any single rotating drum (see Figure 2.3).
• the three steps within the coating operation forming a tumbling bed, dusting step, spraying step
• coated edible cores emerge from the exit end of one drum and pass into the entrance end of the next drum, and so on.
• a series of drums is especially useful for applying multiple dough layers onto individual edible cores (e.g., texture layer followed by a flavor layer, crunchy texture layer followed by a crisp texture layer).
• Edible cores suitable ..for use in the , instant invention include nuts such as. almonds, cashews, Brazil nuts, filberts, peanuts, pecans, macadamia nuts and walnuts.
• Other suitable edible cores include seeds, beans, fruits, meats, cereals, particulates thereof, and agglomerates thereof.
• almost any edible core is coatable if it can readily tumble within the tumbling bed described herein.
• the edible core should be capable of tumbling randomly along any of its axes.
• substantially spherical cores e.g., peanuts
• non-spherical cores e.g., cashews, almonds, pecans
• the edible cores for use in the instant process are preferably peanuts.
• the tumbling bed of edible cores comprises non-overlapping parallel wet and dry zones.
• the wet zone is defined by the area of the tumbling bed that is continuously sprayed with a hydrating liquid described hereinafter.
• the dry zone is defined by the area of the tumbling bed that is continuously dusted with a farinaceous powder also described hereinafter.
• the non-overlapping wet and dry zones are generally rectangular and have separate but substantially major dimensions, wherein each major dimension extends toward the exit and entrance ends of the tumbling bed.
• the tumbling bed can, in fact, comprise several sequential and distinct wet and dry zones which can be positioned in various relationships to each other so long as the wet and dry zones do not overlap.
• FIGs 2.1, 2.2, 2.3 and 2.4 Examples of suitable wet and dry zone configurations are illustrated in Figures 2.1, 2.2, 2.3 and 2.4. It is important that the major dimension of the wet zone(s) not extend beyond the major dimension of the dry zone(s) toward either end of the tumbling bed. If the major dimension of the wet zone extends beyond that of the dry zone, the edible cores in the tumbling bed will tend to aggregate. Preferably, one or more of the major dimensions of the dry zone(s) extend beyond the corresponding major dimension of the wet zone(s) (see Figure 2.2).
• the major dimension at the entrance end of the dry zone extends up to about 4 inches beyond the corresponding dimension of the wet zone, and the major dimension at the exit end of the dry zone extends at least about 4 inches, most preferably from about 6 to 8 inches beyond the corresponding dimension of the wet zone.
• a hydrating liquid is sprayed continuously onto the tumbling bed to form the wet zone of the bed.
• the edible cores in the tumbling bed rotate repeatedly through the wet zone, their surfaces are repeatedly hydrated with the hydrating liquid.
• the hydrating liquid preferably comprises up to about 100% by weight of water and from about 0 to 60% by weight of sugar.
• the hydrating liquid can also contain seasoning, salt, modified pregelatinized starch, gums, flavoring, maltodextrin, oil/shortening, coloring and dairy products.
• Suitable sugars for use in the instant process include granulated, powdered and syrup sugars.
• Suitable syrups include corn syrup, high fructose corn syrup, honey, maple syrup, imitation maple syrup, high maltose syrup, rice syrup, molasses, sorghum syrup and syrups made from sucrose, glucose, fructose and invert sugar.
• the rate at which the hydrating liquid is sprayed onto the wet zone is carefully controlled.
• the spraying rate will affect the degree of hydration of the forming dough coating and, accordingly, the texture of the crisp coating produced therefrom. Excessive spraying rates can also cause aggregation of the tumbling edible cores.
• the spraying rate is determined primarily by 1) the depth of the tumbling bed, 2) the composition of the hydrating liquid and the separately dispensed farinaceous powder, 3) the rotation rate of the tumbler coater, 4) the rate at which the edible cores pass through the tumbling bed, and 5) the rate at which the farinaceous powder is dusted onto the dry zone of the tumbling bed.
• the hydrating liquid should be sprayed over a broad area of the tumbling bed.
• the area so sprayed then defines the wet zone of the tumbling bed. It is important to avoid spraying any of the hydrating liquid directly onto the rotating surface of the tumbler coater. Failure to avoid such direct spraying can result in dough and edible core adhesion to the rotating surface. This build up can disrupt the motion of the edible cores in the tumbling bed. Disrupting this motion can reduce the uniformity of the dough coating around the individual edible cores. It can also result in aggregation of the edible cores in the tumbling bed. Consequently, when such residues develop on the rotating surfaces, the continuous coating process must be interrupted and the rotating surfaces cleaned.
• the wet zone comprises a series of wet zones positioned along the longitudinal axis of the tumbling bed.
• the wet zones are separated by recovery zones, e.g., two wet zones and an intermediate recovery zone.
• Recovery zones are areas of the tumbling bed that are subjected to neither the dusting nor the spraying procedures described herein.
• the series is in parallel with but does not overlap a continuous dry zone. Accordingly, each wet zone and recovery zone in the series is in parallel with the same non-overlapping continuous dry zone (see Figure 2.3).
• the recovery areas help prevent build-up on the rotating surface and aggregation of the edible cores in the tumbling bed.
• the longitudinal dimension of the recovery zones should be sufficient to reestablish the free-flowing nature of the edible cores in the tumbling bed. For example, when higher weight ratios of hydrating liquid to farinaceous powder are applied to the parallel non-overlapping wet and dry zones, the recovery zones may need to be longer.
• the hydrating liquid can be sprayed onto the wet zone by conventional spraying means.
• any spraying or dripping device that can deliver the hydrating liquid to the wet zone in the manner described hereinbefore can be used in d e spraying step.
• Suitable spraying devices include pneumatic spray nozzles, drip manifolds, and manifolds with attached spray nozzles connected to a pump or pressurized vessel. ii. Dusting step
• a farinaceous powder is continuously dusted onto die dry zone of the tumbling bed.
• the edible cores repeatedly rotate through both the wet and dry zones, they are repeatedly coated by the farinaceous powder in die dry zone and the hydrating liquid in the wet zone thereby forming a farinaceous dough around the individual edible cores.
• a farinaceous dough means material comprising flour and water that when cooked is expandable into a crisp material.
• farinaceous flour means finely ground cereal grains or the starch component thereof.
• the rate at which the farinaceous powder is applied to the dry zone is carefully controlled. The rate is preferably maintained at the point at which the tumbling edible cores no longer have a tendency to adhere and form aggregates. If the dusting rate is too low, the edible cores will form aggregates. If the dusting rate, is, too, high, doughy particulates will form among the dough coated edible cores.
• the weight ratio of the farinaceous powder to the hydrating liquid applied to die tumbling bed will typically be from about 1:2 and 5:1, more typically from about 1:1 to 2:1.
• the farinaceous powder contains flour, preferably from about 20 to 100%, more preferably from about 35 to 95% by weight of flour.
• the farinaceous powder further comprises from about 0 to 50%, more preferably from about 5 to 40% by weight of pregelatinized starch.
• the pregelatinized starch is preferably a pregelatinized modified waxy starch.
• Flours suitable for use in the dusting step include nut flour and cereal grain flours derived from wheat, rice, oats, corn, barley, rye or mixtures thereof. Rice flour is preferred.
• the farinaceous powder can also contain seasoning, flavoring, leavening agents, sugar, salt, fiber, or other fine particulates that can adhere to the edible cores during the continuous process.
• the combined composition of the farinaceous powder and the hydrating liquid so applied to the tumbling bed of edible cores comprise flour, starch and sugar such that the weight ratio of flour and starch to sugar is from about 0.5:1 to 30:1, preferably from about 1.5:1 to 10:1.
• the flour and starch are provided primarily by the farinaceous powder.
• the sugar is typically provided by the hydrating liquid but it can be provided by the hydrating liquid and/or the farinaceous powder.
• the farinaceous dough coating formed on the individual edible cores must also contain flour, starch and sugar in diese weight ratios.
• the area of the dry zone so extended is most preferably dusted with a native ungelatinized starch. This reduces die adhesive tendency of the dough-coated edible cores during cooking. Accordingly, the vertical depth of the bed of edible cores in die cooking step can be increased. This further increases the production rate at which the process described herein can operate.
• the farinaceous powder can be dusted onto the dry zone by conventional means.
• any device diat can deliver the farinaceous powder to die dry zone in the manner described hereinbefore can be used.
• Such devices include auger feeders, conveyor feeders and vibratory feeders.
• die dough-coated edible cores are dien cooked until crisp.
• the cooking can involve conventional baking, microwaving or oil frying methods.
• the cooking involves a continuous baking operation.
• the dough-coated edible cores emerging on a continuous bases from the exit end of die tumbling bed are conveyed, by continuous belt conveyor or like means, through a baking zone.
• the baking zone comprises an oven and a means for conveying the dough-coated edible cores theredirough. Air temperatures within the baking zone are generally from about 220oF to 400oF, more typically from about 280oF to 350oF.
• Baking or residence times for the dough-coated edible cores in the baking zone are generally from about 10 to 60 minutes, more typically from about 12 to 30 minutes.
• the baking can also provide partial or complete roasting of the nuts as well.
• the coated edible cores can be further treated or coated with salt, oil, starch and or gum solutions, sugar, seasoning, flavorants, chocolate, candy and so on.
• the coated edible cores can also be further coated with farinaceous materials by way of conventional batch processing methods or die continuous coating process described herein.
• T Thhee process described herein provides a highly efficient means for providing edible coorreess with a substantially uniform, crisp farinaceous coating.
• the rate of production of d ese coated products is increased dramatically over existing coating methods.
• this continuous process can be used to produce up to about 10,000 lbs/hr of coated peanuts on conventional machinery. Modification of such machinery could provide a means of further increasing these production rates.
• a batch operation can provide only about 600 lbs/hr of coated peanuts per batch pan.
• production costs are reduced. It is well known that providing edible cores with crisp farinaceous coatings is costly. The cost is due largely to die batch processing med ods heretofore thought necessary for making these coated products. Compared to batch processing methods, die continuous process described herein is less labor intensive, requires fewer machines and uses less factory space.
• the continuous process also allows for the consistent production of evenly coated edible cores. That is, undesirable variations in coating compositions experienced by separate batch operations is greatly reduced by this continuous process.
• the crisp farinaceous coating produced by die process is remarkably uniform and exhibits an improved crispy texture.
• the crisp uniform coating preferably represents from about 15 to 70%, more preferably from about 25 to 60%, most preferably from about 30 to 50% by weight of the coated edible core. This substantially uniform coating tends to preserve the natural shape of the underlying edible core (e.g., coated peanuts retain a peanut-like shape).
• FIG. 1.1, 1.2 and 1.3 A suitable device for use in the instant process is illustrated in Figures 1.1, 1.2 and 1.3.
• the tilted rotating drum 101 has an entrance end 102 and an exit end 103.
• a retainer ring 104 is fixed within the rotating drum 101 toward die exit end 103 of die drum.
• the rotating surface of the drum contains ribbings 112.
• a spray bar 107 with two attached spray nozzles 108 is positioned within die rotating drum.
• an auger feeder 111 is fixed to die flour hopper 109 and positioned within die drum 101.
• the tumbling bed of edible cores 106 comprises parallel non-overlapping wet 1 13 and dry zones 114.
• the hydrating liquid and the farinaceous powder compositions listed below are prepared by conventional means.
• Raw blanched peanuts (1000 lbs/hr) are passed dirough a tilted (2.5o) drum rotating at 15 ⁇ .
• the rotating drum (12ft x 3ft) has a ribbed rotating surface and a 4 inch retention ring positioned 28.5 inches from die exit end of die drum.
• the depdi of die tumbling bed increases from a single peanut layer at the entrance end of die bed to about 4 inches at the retention ring.
• Two spray nozzles continuously deliver die hydrating liquid to die wet zone of the tumbling bed while an Accurate feeder continuously dusts a parallel non-overlapping dry zone with the farinaceous powder.
• the major dimension of the dry zone is 55 inches.
• the wet zone comprises two sequential wet zones each with a 14-16 inch major dimension.
• the two wet zones are separated by a 12 inch recovery zone.
• the major dimension of the dry zone extends beyond die major dimension of die wet zones at die entrance end by 4 inches and at die exit end by 7 inches.
• the weight ratio of farinaceous powder to hydrating liquid applied to die tumbling bed is about 1.1:1.
• the spray nozzle toward the entrance end delivers about 40% by weight of the hydrating liquid while the other spray nozzle delivers about 60% by weight of die hydrating liquid.
• Peanuts having a uniform dough coating continuously emerge from the exit end of die rotating drum.
• the dough contains flour, starch and sugar in a weight ratio of flour and starch to sugar of 6:1.
• the dough-coated peanuts are roasted until crisp (about 12 minutes) in a Proctor Shwartz oven with zone temperatures of 300oF and 305oF.
• the crisp uniform coating around die individual nuts represents about 38 to 40% by weight of the coated product.
• the crisp coated peanuts from EXAMPLE I are then sprayed with an adhesive liquid, dusted with seasoning, and dien lightly roasted at 270oF for 4-5 minutes.
• the weight ratio of adhesive liquid to seasoning is 1:2.
• the adhesive liquid contains granulated sugar (30 wt%), salt (0.5 wt%), gum or modified starch (4.0 wt%) and water (51.5 wt%).
• the seasoned nuts are sprayed widi peanut oil and dien packaged in glass containers.
• Raw unblanched peanuts are coated and baked as in EXAMPLE 1 using the following materials.
• Farinaceous powder Hvdrating liquid pregel modified waxy starch 37 wt% water 61.6 wt% rice flour 18 wt% honey 4.5 wt% whole wheat flour 6 wt% sugar 28.9 wt% oat flour 31 wt% malt flavor 5 wt% baking powder 1.8 wt% salt 2.3 wt% sugar (6x) 3.9 wt%
• the uniform dough coating formed around die individual peanuts prior to baking comprises flour, starch and sugar in a weight ratio of flour and starch to sugar of 3:1. After baking, the crisp farinaceous coating represents about 35% by weight of die coated product.
• the baked coated peanuts are then sprayed with an adhesive liquid, dusted with seasoning (honey roasted seasoning), and then dried in a roasting oven at 280oF for 4-5 minutes.
• seasoning honey roasted seasoning
• the weight ratio of adhesive liquid to seasoning is 1:5.
• the adhesive liquid contains water (64wt%), honey (16 wt%), sugar (5 wt%) and film-forming modified starch (5 wt%).
• the seasoned nuts are sprayed widi peanut oil and then packaged in glass containers.
• EXAMPLE 4 Rather than seasoning the baked coated peanuts in EXAMPLE 3, the coated peanuts are further coated with a light milk or dark chocolate.
• the chocolate coating is applied to the coated nuts via conventional pan coating methods.

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• Chemical & Material Sciences (AREA)
• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Food Science & Technology (AREA)
• Polymers & Plastics (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Health & Medical Sciences (AREA)
• Nutrition Science (AREA)
• Confectionery (AREA)
• General Preparation And Processing Of Foods (AREA)

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• 1993
  • 1993-02-16 US US08/017,551 patent/US5433961A/en not_active Expired - Lifetime
• 1994
  • 1994-02-10 AU AU62396/94A patent/AU6239694A/en not_active Abandoned
  • 1994-02-10 WO PCT/US1994/001581 patent/WO1994018858A1/en not_active Application Discontinuation
  • 1994-02-10 JP JP6519055A patent/JPH08509858A/ja active Pending
  • 1994-02-10 CA CA002155676A patent/CA2155676C/en not_active Expired - Lifetime
  • 1994-02-10 CN CN94191497A patent/CN1043557C/zh not_active Expired - Fee Related
  • 1994-02-10 EP EP94909615A patent/EP0684773A1/en not_active Withdrawn

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